Self-expanding device delivery apparatus with dual function bump

ABSTRACT

A self-expanding element delivery apparatus includes a catheter having an inner lumen, a self-expanding element, and a delivery wire disposed within and extending through the inner lumen and the self-expanding element. The self-expanding element has a proximal, distal, and an intermediate portion. The element has anchor members, a compressed configuration fitting within the inner lumen, and an expanded configuration dimensioned larger than the catheter. The delivery wire also has proximal and distal portions, an intermediate portion, a dual function bump member disposed approximate to the intermediate portion, and a pusher bump member disposed approximate to the proximal portion of the delivery wire. A bump member distance between the dual function bump member and the pusher bump member is such that so that only one of the dual function bump member and the pusher bump member can contact one of the anchor members.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 15/281,974, filed on Sep. 30, 2016, the content of which is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

This invention relates generally to devices for interventional therapeutic treatment or vascular surgery for treatment of defects in the vasculature, and more particularly concerns a system for delivering a self-expanding device or stent to a treatment site in a body lumen of a patient.

BACKGROUND

Cardiac stents, which are an example of a self-expanding device, are inserted into a blood vessel to provide an open path within the blood vessel, have been widely used in intravascular angioplasty treatment of occluded cardiac arteries, and in other applications. Stents are often deployed by use of inflatable balloons, or mechanical devices which force the stent open, thereby reinforcing the artery wall and provide a clear through-path in the center of the artery after the angioplasty procedure to prevent restenosis. The use of placement techniques, such as balloons or mechanical expansions of the type often found to be useful in cardiac surgery, are relatively less useful in vasoocclusive surgery, particularly when tiny vessels, such as those found in the brain, are to be treated.

Other stents are self expanding and are just deployed inside of the vascular. Their self-expanding nature allows them to be smaller as well as the devices to deploy them. There are different techniques to deploy the stents, and each has benefits and drawbacks. One expandable stent and delivery system is known that includes an expandable stent having proximal and distal anchor members mounted on proximal and distal legs extending proximally and distally from the stent. The proximal and distal anchor members of the expandable stent are mounted in gaps formed between proximal, intermediate and distal cylindrical members disposed on and spaced apart along an elongated core member. However, pushing the device distally in a catheter from the proximal end of the device is not optimal, because application of force in a distal direction on the proximal end of the stent can axially compress the stent, and can cause the stent to expand radially. Likewise, retracting the device proximally may not be optimal either, because application of force in a proximal direction on the distal end of the stent also can axially compress the stent, and can cause the stent to expand radially.

The deployment techniques fall into two categories, one is where the members are deployed outside the stent to pull or push accordingly depending on distal or proximal placement, or sometimes both. See, U.S. Pat. Nos. 6,123,723, 6,280,465, and US Publication No. 2011/0307049. Other techniques deploy the members inside of the stent. See, US Publication No. 2014/0277360, and U.S. Pat. Nos. 5,702,418, and 6,955,685. However, self-expanding device delivery systems with multiple members pose two problems:

1) After the physician has deployed the self-expanding device, he/she must re-sheathe the delivery wire back into the microcatheter, to then dispose of the wire. When recapturing the delivery wire, the members of the delivery system can get caught on the deployed device, and can subsequently alter the position of the device in the anatomy. The more members on the wire, the more often this can happen.

2) The more members on the delivery wire, the more difficult it is to manufacture. In order to build the delivery system, a manufacturer can either secure polymer/metal sleeves onto a core wire, or grind down a core wire to create members on a wire. The more members on a delivery wire, the more material must be used to add and secure members, or, the more the grind profile has to change to accommodate all of the members.

Thus, would be desirable to provide a delivery system for expandable stents that offers the flexibility of engaging the device and for pushing and/or pulling the device proximally or distally as desired. Also desirable is a simplified manufacturing method.

SUMMARY

The dual function delivery system described below reduces these two problems by combining certain members into one. This invention provides a unique advantage of a delivery system that includes one feature that can perform two functions.

Thus, a self-expanding element delivery apparatus can include a catheter having an inner lumen, a self-expanding element, and a delivery wire disposed within and extending through the inner lumen and the self-expanding element. The self-expanding element has a proximal end, a distal end, an intermediate portion between the proximal and distal ends, and a proximal and distal anchor member disposed accordingly. The element is configured to have a compressed configuration dimensioned to fit within the inner lumen of the catheter, and an expanded configuration dimensioned larger than the catheter. The self-expanding element is in the compressed configuration when disposed within the inner lumen, and is in the expanded configuration when disposed outside the inner lumen. The delivery wire also has a proximal and distal portions, an intermediate portion located between, a dual function bump member disposed approximate to the intermediate portion of the delivery wire, and a pusher bump member disposed approximate to the proximal portion of the delivery wire. There can be a bump member distance between the dual function bump member and the pusher bump member so that only one of the dual function bump member and the pusher bump member can contact one of distal anchor member and the proximal anchor member.

In another example, the delivery wire is moveable within the inner lumen and the self-expanding element, and the dual function bump member and the pusher bump member are configured to engage at least one of the proximal and distal anchor members when the delivery wire is translated longitudinally. Also a force applied longitudinally to the delivery wire is transmitted through at least one of the bump members to at least one of the anchor members to move the self-expanding element through the catheter when the self-expanding element is in the compressed configuration within the catheter.

Further, when the delivery wire is moved distally, the dual function bump member contacts the distal anchor member and the pusher bump member does not contact the proximal anchor member during an initial deployment phase. Then, when the delivery wire is moved distally and the distal end of the self-expanding element is outside the catheter and expanded and the proximal end of the self-expanding element is still in the compressed configuration, the pusher bump member contacts the proximal anchor member and the dual function bump member does not contact the distal and the proximal anchor members during a final deployment phase. After the final deployment phase, the self-expanding element is in the expanded configuration.

An example of a recapture phase can occur when the distal end of the self-expanding element is outside the catheter and expanded and the proximal end of the self-expanding element is still in the compressed configuration. When the delivery wire is moved proximally the dual function bump member contacts the proximal anchor member and the pusher bump member does not contact the proximal anchor member during. Also, after the recapture phase, the self-expanding element is in the compressed configuration inside the catheter.

An example of a method of deploying a self-expanding element with a catheter, delivery wire and the self-expanding element including distal and proximal anchor members thereon, the steps include disposing a dual function bump member on the delivery wire between the proximal and distal anchors and disposing a pusher bump member outside of the self expanding element proximal of the proximal anchor. To deploy the self-expanding element, a user distally moves the delivery wire and engages the dual function bump member to the distal anchor member and unengages the pusher bump member. Next, the pusher bump member can be engaged to the proximal anchor member and disengaging the dual function bump member, thus, fully deploying the self-expanding element. As used in the example herein, “unengaging” connotes that in the first instance when the dual function bump is engaged, the pusher bump is not engaged with the proximal anchors and never engages with the distal anchors. Also, that the when the dual function bump is engaged, the pusher bump is not engaged either during deployment or recapture.

Another example to recover a partially deployed self-expanding element has the steps of proximally moving the delivery wire and engaging the dual function bump member to the proximal anchor member and disengaging the pusher bump member.

BRIEF DESCRIPTION OF THE DRAWINGS

This invention is described with particularity in the appended claims. The above and further aspects of this invention may be better understood by referring to the following description in conjunction with the accompanying drawings, in which like numerals indicate like structural elements and features in various figures. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. The drawing figures depict one or more implementations in accord with the present teachings, by way of example only, not by way of limitation.

FIG. 1 is an enlarged partial cross-sectional view of an apparatus for delivering and releasing a self-expanding element to a treatment site in a patient's body lumen, according to an example of the invention;

FIG. 2 is an enlarged partial cross-section view of the system apparatus within the body lumen and the self-expanding element in the compressed configuration;

FIG. 3 is a cross-section view illustrating an expanded configuration of the self-expanding element within the patient's body lumen;

FIG. 4 is a section of the delivery wire with the dual function bump member and pusher bump member;

FIG. 5 is an enlarged partial cross-section view, similar to FIG. 2, with a portion of the self-expanding element cut away to expose the bump members on the delivery wire;

FIG. 6 is an enlarged partial cross-sectional view illustrating the initial deployment phase and pushing the self-expanding element distally;

FIG. 7 is an enlarged partial sectional view of final deployment phase where the self-expanding element is moved distally with a proximal portion of the self-expanding stent compressed within a deployment catheter and a distal portion of the self-expanding stent expanded within the patient's body lumen;

FIG. 8 is an enlarged partial cross-sectional view illustrating the recapture phase of pulling the self-expanding element proximally into the catheter; and

FIG. 9 is a flow diagram illustrating an example of a method of using the apparatus of the present invention.

DETAILED DESCRIPTION

In the following detailed description, numerous specific details are set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well known methods, procedures, components, and/or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings.

Examples of the present invention provide for an apparatus 100 that can deliver and release a self-expanding element 200 to a treatment site in a patient's body lumen (e.g. vasculature) 10. As is illustrated in FIG. 1-3, the apparatus 100 includes a catheter 102 having an inner lumen 104, the self-expanding element 200 can have an inner space (not illustrated), a proximal end 202, a distal end 204, and an intermediate section 206 located between the ends 202, 204. Typically, the self-expanding element 200 has a compressed configuration and an expanded configuration. In the compressed configuration, as illustrated in FIGS. 1 and 2, the self-expanding element 200 can be dimensioned to fit within the inner lumen 104 of the catheter 102. The catheter 102 can aid in constraining the self-expanding element 200 so it does not expand when contained within the catheter 102. Other elements can be used to constrain the self-expanding element 200 as are known in the art.

In the expanded configuration, as illustrated in FIG. 3, the self-expanding element 200 expands to fit the dimensions of the patient's body lumen 10. The expanded dimension of the self-expanding element 200 allows the apparatus 100 to pass therethrough, to either advance to a second location or be withdrawn. The self-expanding element 200 can be expandable under its inherent proprieties, based at least on its original shape and the nature of the materials that make up the element. Examples of the self-expanding element 200 can be one of pear shaped, ovoid, and elliptical when at its expanded diameter. The construction of the self-expanding element 200 is known to those of skill in the art.

The self-expanding element 200 can also include one or more anchor members 208, 210, such as proximal anchor members 208 at the proximal end 202 of the self-expanding element 200, and distal anchor members 210 disposed at the distal end 204 of the self-expanding element 200. The anchor members 208, 210 may be projections which extend generally parallel to a longitudinal axis of the self-expanding element 200 and extend downward toward the longitudinal axis of the self-expanding element 200. The anchor members 208, 210 can serves as a radiopaque marker for improved visualization during the deployment of the self-expanding element 200 within the body lumen 10. The anchor members 208, 210 can be used to align the self-expanding element 200 so it can be pushed and pulled through the catheter 102 without damage or deformation.

FIGS. 4-8 illustrate that the apparatus 100 can also include the delivery wire 106 disposed within and extending through the lumen 104 of the catheter 102. The delivery wire 106 has a proximal portion 108, a distal portion 110, and an intermediate portion 112 located between the proximal and distal portions 108, 110 of the delivery wire 106. The delivery wire 106 can have a dual function bump member 114 and a pusher bump member 116 extending radially outwardly from the delivery wire 106 and configured to engage the anchor members 208, 210 when the delivery wire 106 is translated longitudinally toward the one or more anchor members 208, 210. Force applied longitudinally to the delivery wire 106 can be transmitted through one or both of the bump members 114, 116 to the one or more anchor members 208, 210 to the self-expanding element 200. This acts to move the self-expanding element 200 through the catheter 102 when the self-expanding element 200 is constrained within the catheter 102. This is explained in more detail below.

As illustrated, the dual function bump member 114 is disposed between the proximal and distal anchor members 208, 210, toward the intermediate section 206 of the self-expanding element 200 and/or the intermediate portion 112 of the delivery wire 106. This places the dual function bump member 114 “inside” the self-expanding element 200. The pusher bump member 116 on the other hand, is disposed on the proximal portion 108 of the delivery wire 106, proximal to the proximal anchor members 208 of the self-expanding element 200. This places the pusher bump member 116 “behind” the self-expanding element 200. This placement facilitates both the deployment and retrieval of the self-expanding element 200 from the catheter 102 into the body lumen 10.

Turning first to deployment, FIG. 6 illustrates the initial deployment phase. Here, as the delivery wire 106 is moved distally, the dual function bump member 114 contacts the distal anchor members 210 of the self-expanding element 200. In this phase, the dual function bump member 114 is pushing the self-expanding element 200 from the “inside.” The pusher bump member 116 is not in contact with the proximal anchor members 208 during this phase. By having only the dual function bump member 114 pushing during the initial deployment phase there is reduced localized buckling and/or radial expansion of the self-expanding element 200. This reduces the force needed to drive the self-expanding element 200 distally out of the catheter 102.

In the final deployment phase, as illustrated in FIG. 7, the self-expanding element 200 is partially outside of the catheter 102 and partially expanded. The distal end 204 is expanded, while the proximal end 202 remains compressed. In the expanded state, the distal anchor members 210 have expanded away from both the delivery wire 106 and the dual function bump member 114. Now, the dual function bump member 114 no longer contacts the self-expanding element 200 and cannot apply distal or “forward” force to the self-expanding element 200. To deploy the remainder of the self-expanding element 200, the delivery wire 106 is advanced until the pusher bump member 116 contacts the proximal anchor members 208. The pusher bump member 116 is able to contact the proximal end 202 of the self-expanding element 200 since that section is still compressed inside the catheter 102. The pusher bump member 116 is “outside” of the self-expanding element 200 and pushes the remainder of the self-expanding element 200 completely outside the catheter 102. This allows the self-expanding element 200 to fully expand and be positioned inside the body lumen 10. Once fully expanded, the self-expanding element 200 has a larger diameter than the delivery wire 106, the bump members 114, 116 and the catheter 102, allowing this portion of the apparatus 100 to pass therethrough and be removed. This full deployment is illustrated in FIG. 3.

Given the above, the dual function bump member 114 and the pusher bump member 116 have a bump member distance 118 therebetween. The bump member distance 118 can be calibrated based on the size of the self-expanding element 200. The bump member distance 118 needs to be such that only one of the bump members 114, 116 contacts the anchor members 208, 210 at a given time when the delivery wire 106 is being moved either proximally or distally. Said another way, when the dual function bump member 114 contacts one set of the anchor members 208, 210, the pusher bump member 116 is not in contact with the proximal anchor members 208. Then, when the pusher bump member 116 is in contact with the proximal anchor members 208, the dual function bump member 114 is not in contact with either the distal anchor members 110 or the proximal anchor members 208. Another example of the bump member distance 118 is that it must be greater than a distance from the proximal piece of the distal anchor member 210 and the proximal piece of the proximal anchor member 208.

In some instances, the self-expanding element 200 needs to be recaptured before full deployment. Once reason for recapture can be that the self-expanding element 200 needs to be better placed within the body lumen 10. FIG. 8 illustrates the recapture phase. Here, the self-expanding element 200 is pulled back/recaptured into the catheter 102 when the delivery wire 106 is pulled proximally. The dual function bump member 114 now moves proximally away from the distal anchor members 210 to engage the proximal anchor members 208. This engagement now pushes the proximal anchor members 208 proximally and forces the self-expanding element 200 to compress back into the catheter 102 until it is again fully enclosed in the inner lumen 104 of the catheter 102. During the recapture phase, the pusher bump member 116 does not contact the proximal anchor members 208 or the self-expanding element 200.

FIG. 9 illustrates an example of the method of the present invention. In an apparatus 100 as described above, a dual function bump member 114 can be disposed between proximal and distal anchors 208, 210 of a self expanding element 200 (step 300). A pusher bump member 116 can be disposed outside of the self expanding element 200 on the proximal side (step 302). The self-expanding element 200 can be deployed (step 304) by distally moving the delivery wire 106 (step 305) till engaging the dual function bump member 114 to the distal anchor members 210 while the pusher bump member 116 remains unengaged (step 306). Next, the dual function bump member 114 is disengaged when the pusher bump member 116 engages the proximal anchor members 208 of the self-expanding element 200 (step 308). Finally, the self-expanding element 200 is fully deployed and the apparatus 100 can be removed (step 310).

In a recapture method example, any time before full deployment, the self-expanding element 200 can be recovered into the catheter 102. This includes the step of moving the delivery wire 106 proximally (step 312) to engage the dual function bump member 114 to the proximal anchor member 208 (step 314) while the pusher bump member 116 is unengaged (step 316).

Note that certain features of the apparatus 100 can be formed from materials that have a shape memory structure. For example, a metal alloy such as nickel titanium (NiTi), also known as Nitinol. Other elements may be formed of a non-superelastic material, such as spring steel or MP35N, an alloy of 35% nickel, 35% cobalt, 20% chromium, and 10% molybdenum, by weight. Features may be laser cut from the material, secure onto the delivery wire, or the delivery wire can be grinded down to create the above described elements.

While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that the teachings may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all applications, modifications and variations that fall within the true scope of the present teachings. 

What is claimed is:
 1. A method comprising: selecting a self-expandable stent comprising a distal anchor member approximate its distal end and a proximal anchor member approximate its proximal end; selecting a delivery wire comprising a first engagement bump and a second engagement bump; positioning the self-expandable stent and the delivery wire in a delivery configuration as follows: positioning the self-expandable stent within a lumen of a catheter, and positioning the delivery wire to extend through the self-expandable stent such that the first engagement bump is confined inside the stent by the proximal anchor member and the distal anchor member and such that the second engagement bump is positioned in the proximal direction in relation to the proximal anchor member; delivering the self-expandable stent through the lumen of the catheter by moving the delivery wire distally while the first engagement bump pushes the distal anchor member distally and while the second engagement bump is unengaged to the stent; and retracting at least a portion of the self-expandable stent proximally through the lumen of the catheter by moving the delivery wire proximally while the first engagement bump pushes the proximal anchor member proximally and while the second engagement bump is unengaged to the stent.
 2. The method of claim 1 further comprising: partially implanting the self-expandable stent as follows: expelling the distal anchor member from a distal end of the catheter, thereby disengaging the first engagement bump from the distal anchor member, pushing the delivery wire distally to engage the second engagement bump to the proximal anchor member and push the proximal anchor member distally while the first engagement bump is disengaged from the distal anchor member, and maintaining the proximal anchor member within the lumen of the catheter.
 3. The method of claim 2 further comprising: completely implanting the self-expandable stent as follows: pushing the second engagement bump distally against the proximal anchor member, expelling the proximal anchor member from the distal end of the catheter, thereby disengaging the second engagement bump from the proximal anchor member, and anchoring the stent within a lumen of a blood vessel by expanding the proximal anchor member against a wall of the blood vessel and expanding the distal anchor member against a wall of the blood vessel.
 4. The method of claim 2 further comprising: retracting the entirety of the partially implanted self-expandable stent into the lumen of the catheter as follows: moving the delivery wire proximally while the first engagement bump pushes the proximal anchor member proximally and while the second engagement bump is unengaged to the stent, and collapsing the distal anchor member into the lumen of the catheter.
 5. The method of claim 1, wherein selecting the self-expandable stent further comprises: selecting the self-expandable stent such that when the stent is in the delivery configuration, the stent comprises a length measurable between a proximal end of the distal anchor member and a proximal end of the proximal anchor member, and wherein selecting the delivery wire further comprises: selecting the delivery wire comprising a fixed bump member distance measurable from a distal side of the first engagement bump to a distal side of the second engagement bump such that the fixed bump member distance measures greater than said length.
 6. The method of claim 1, wherein positioning the self-expandable stent and the delivery wire in a delivery configuration further comprises: positioning the self-expandable stent within the lumen of the catheter such that the self-expandable stent is constrained by the lumen of the catheter.
 7. The method of claim 1, wherein delivering the self-expandable stent through the lumen of the catheter further comprises: delivering the self-expandable stent distally through the lumen of the catheter while the stent is solely engaged to the delivery wire at the first engagement bump.
 8. The method of claim 1, wherein retracting at least the portion of the self-expandable stent proximally through the lumen of the catheter further comprises: retracting at least the portion of the self-expandable stent proximally while the stent is solely engaged to the delivery wire at the first engagement bump.
 9. A method comprising: moving a self-expanding stent distally through a catheter by pushing a dual function bump member on a delivery wire distally against a distal anchor member on a distal end of the stent; partially deploying the stent by first expanding the distal anchor member radially away from the dual function bump member thereby disengaging the dual function bump member from the distal anchor member and next by pushing a pusher bump member on the delivery wire distally against a proximal anchor member on a proximal end of the stent; and recovering the partially deployed stent by first pulling the delivery wire proximally to disengage the pusher bump member from the proximal anchor member and next by pulling the delivery wire proximally to push the dual function bump member proximally against the proximal anchor member.
 10. The method of claim 9, further comprising: completing deployment of the stent by expanding the distal anchor to anchor within a blood vessel, expanding the proximal anchor to anchor within the blood vessel, and disengaging the delivery wire from the stent.
 11. The method of claim 9, further comprising: sizing the delivery wire such that when the stent is moved distally through the catheter, a distal side of the dual function bump member is engaged to a proximal end of the distal anchor member, a distal side of the pusher bump member is positioned in the proximal direction in relation to a proximal end of the proximal anchor member, and the pusher bump member is unengaged to the proximal anchor member.
 12. The method of claim 9, further comprising: constraining the self-expandable stent by a lumen of the catheter.
 13. The method of claim 9, further comprising: engaging the delivery wire to the stent solely at the dual function bump member of the delivery wire and solely at the distal anchor member of the stent while moving the stent distally through the catheter.
 14. The method of claim 9, further comprising: engaging the delivery wire to the stent solely at the dual function bump member of the delivery wire and solely at the proximal anchor member of the stent while pulling at least a portion of the stent proximally into the catheter.
 15. A method comprising: traversing a collapsed stent comprising a distal anchor member and a proximal anchor member through a lumen of a catheter by moving a distal engagement bump on a delivery wire to push distally against the distal anchor member while the distal engagement bump is positioned inside the stent and while a proximal engagement bump on the delivery wire is unengaged to the stent and positioned on a proximal side of the proximal anchor; partially implanting the stent by first expelling the distal anchor member from a distal end of the catheter causing the distal engagement bump to disengage the distal anchor member and next by moving the proximal engagement bump to push distally against the proximal anchor member while the distal engagement bump is unengaged to the stent; and retracting at least a portion of the stent proximally through the lumen of the catheter by moving the distal engagement bump to push proximally against the proximal anchor member.
 16. The method of claim 15, further comprising: completely implanting the stent by expelling the proximal anchor member from the distal end of the catheter causing the proximal engagement bump to disengage the proximal anchor member.
 17. The method of claim 16, wherein completely implanting the stent further comprises anchoring the distal anchor member with a blood vessel and anchoring the proximal anchor member within the blood vessel.
 18. The method of claim 15, further comprising: constraining the stent by the lumen of the catheter while the stent is traversed through the lumen.
 19. The method of claim 15, further comprising: engaging the delivery wire to the stent solely at the distal engagement bump of the delivery wire and solely at the distal anchor member of the stent while the stent is traversed distally through the lumen of the catheter.
 20. The method of claim 15, further comprising: engaging the delivery wire to the stent solely at the distal engagement bump of the delivery wire and solely at the proximal anchor member of the stent while at least the portion of the stent is retracted proximally through the lumen of the catheter. 